Working on a Cooler Coyote – Cooler R&D, Part 2: Bracket Fabrication

Prototype Bracket

Last time, we looked at how we began our bracket design and also the location of the oil cooler. Our design has certainly progressed since then. After we were certain of the dimensions of the bracket, we ditched the cardboard for some steel. Using our waterjet the engineers cut out our first functional prototype bracket. The waterjet is one of our newest tools and has been making development a breeze, as it allows us to make much more precise prototypes compared to fabricating them by hand.

Mustang oil cooler bracket

The bracket will be bent and the tabs in the center will fold together to better emulate the stock component. If you have noticed all of the small circles cut out of the front portion of the bracket, we plan to test the strength of the bracket with and without dimples to decide if they are necessary for added strength.

Mustang oil cooler bracket

Once the bracket was bent to shape, the next task was to create the small dowels that stick out of these folded tabs. This was a job for the trusty lathe! Check out some shots of the lathe in action.

Heat Exhanger Prototype

After we had the bracket in its final position, we put together a prototype cooler for fitment purposes to ensure that it would be clear of all important Mustang parts. Here are some photos of our plans for the oil cooler’s general size and shape.

Wouldn’t be more ideal to put the GT oil cooler in the bottom or under side of the bumper to sell too a wider range of people. Quite a few are running prochargers or centrifugal superchargers, even turbos that have intercoolers which already take up the top half. These are the people more in need of an oil cooler.

We were thinking the same thing, which is why plan to leave room for aftermarket intercoolers to sit between the oil cooler and the radiator. Our oil cooler prototype sits flush with the back of the crash beam in order to account for Mustang GTs running forced induction setups. Stay tuned for more photos on this!